ax1331-50/51 installation manual - · pdf filetimken -luri ation installation manual for...

TIMKEN - LUBRICATION

Installation Manual

For AX13X1-50 & AX13X1-51

This Manual is applicable to the AX13X1-50 and AX13X1-51 AXL lubrication kits only. For professional use only.

This print and the ideas and principles represented on the print are the property of Interlube Inc. USA. This print is not to be copied or reproduced (even extracts) without prior

written consent from Interlube Inc. Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or

damage whether direct, indirect or consequential arising out of the use of the information contained herein.

ISF 349 AXL Operation and Maintenance

Applicable Kit(s):

AX13X1-50 with pre-primed grease filled loom

and AX13X1-51 with non-primed loom for customer specific grease or oil lubrication.

Maximum Working Pressure: 1740 psi (120 bar, 12 MPa)

Maximum operating temperature: 140°F/60°C

*(Note that operating close to maximum temperature will effect life of the pump)*

Minimum operating temperature: -31°F/-35°C (with grade 000 grease), 10°F/-12°C (with grade 2 grease).

IP Rating: IP67

Voltage: 110V (50/60Hz)

Power Rating: 4VA

Fuse Rating: 1A

* CONFIDENTIAL- IMPORTANT NOTICE *

Note: Wiring colors may differ from those shown.

INSTALLATION

Only install the Interlube Inc. AXL System if you are suitably

qualified. Read installation instructions before commencing

installation. If in doubt contact Interlube Inc. on +1 (937) 276 4507

PERSONAL PROTECTIVE CLOTHING

You must wear appropriate protective equipment when operating

and servicing the equipment, this is to protect you from serious

injury.

This equipment includes but is not limited to:

Protective eyewear.

Respirators, protective clothing and gloves as recommended by

the Lubricant manufacturer.

PLASTIC PART CLEANING SOLVENT HAZARD

Many solvents can damage plastic parts and cause them to fail, which

could cause serious injury or property damage.

Use only compatible cleaning products.

ENVIRONMENT

Ensure that all Lubricants are responsibly disposed of in accordance

with the manufacturers MSDS sheets and local regulations.

WARNING

AXL Operation and Maintenance II

Installation Warning

EC Declaration of Conformity In accordance with ISO/IEC 17050-1:2010

We Interlube Ltd.

Of 85a St Modwen Rd, Parkway Industrial Estate,

Plymouth, Devon, United Kingdom, PL6 8LH.

I hereby declare that:

Equipment: AX XXXX/X Multi-Line Lubrication System

In accordance with the following Directive (s):

2004/108/EC The Electromagnetic Compatibility Directive

2006/42/EC Machinery Directive

2011/65/EC Restriction of Certain Hazardous Substances

Has been designed and manufactured to the following specifications:

BS EN 61000-6-2:2005, BS EN 61000-6-4:200, EN 60204-1

I hereby declare that the equipment named above has been designed to comply with

the relevant sections of the above referenced specifications. The unit complies with

all essential requirements of the Directives.

Signed:

Name: Richard Butler Position: Divisional Managing Director

Done at: Plymouth, UK Date: 04/01/2016

Document Ref: ISF 328 Issue 3

EC Declaration Of Conformity

III AXL Operation and Maintenance

Installation

1 AXL Operation and Maintenance

Mounting Hole Dimensions

Pump Clearance Requirements

Select a suitable mounting point for the pump on the machinery, preferably in a position where it is protected from debris. Ensure adequate clearance for the looming and re-filling is made (see image below for clearance allowances). Do not mount the pump on to ancillary equipment. Using the pump mounted adhesive template (part number 31867-900), supplied, position and drill the bracket holes (mounting positions and bracket clearances detailed as per the above image). Use bolts, nuts and spring washers supplied to securely mount the pump in position.

Installation


Pumping elements

The AX13X1-50 & -51 AXL series pumps are pre-calibrated with 78036, blue, pumping units (0.04cc output per stroke). The pump timer is preset to switch ‘3’ (6 minutes run and 30 minutes dwell) to meet most industrial applications. However, a selection of pumping -elements with varying outputs are available to suit almost any need:

Making the Looms & Connection

1

REMOVE PLUG

2

POSITION LUBRICATION LINE FROM BEARING FITTING

3

INSERT LUBRICATION LINE INTO BULKHEAD FITTING

The AXL series pumps are pre-loomed from the pumping element to the bulkhead connections on the pump bracket (bulkhead fittings part number: 25487-072). The push fit connectors provide an easy installation of the lines to the bulkhead connectors. The lubrication line should be Interlube ø4mm, semi-rigid, nylon tubing. It is recommended that the tubing is pre-filled with grease to save on the need to prime the system once installed. From the pump position establish the most convenient route for the lubrication lines. It may be preferred to group the lines into looms depending on pump location and quantity and positioning of the grease points. If grouping the lines, into looms, allow sufficient length for connection to the bulkhead outlet connectors and the bearings, making an allowance for movement on the machinery. In conjunc-tion with the ‘Installation Record’ sheet (see page 12), fit the number identification sleeves to the lines at the pump and bearing ends. The loom should be protected along its length with the conduit/ spiral binding/ sleeving and/or tape (for part numbers see Accessories on page 8).

Installation: Working from the furthest point from the pump, feed the lubrication lines through the machine following existing machine services, where possible. Ensure that the lubrication lines are positioned to fit the bearing fittings. Where a bearing is on a moving part, ensure that the line is sufficient to allow for full movement. To avoid rubbing or friction with moving parts, grommets or protective sleeving should be used. Also, depending on the severity of movement, compression fittings may be preferred at the bearing points.

Connecting the lines: Cut each lubrication line to length ensuring a clean, square cut is achieved and connect to the bearing using push fit or compression connectors. ENSURE TUBING IS PUSHED FIRMLY INTO CONNECTOR. TEST THE ASSEMBLY BY PULLING FIRMLY ON THE LINE AFTER - INSTALLATION. To connect to bulkhead fittings on the pump bracket follow steps 1 to 3 as shown above. Remove plug from bulkhead and push the line firmly into the bulkhead. Again, ENSURE THE LINE IS PUSHED FIRMLY INTO CONNECTOR. TEST THE ASSEMBLY BY PULLING FIRMLY ON THE LINE AFTER INSTALLATION. Using the ‘Installation Record’ sheet (see page 12) connect the lines to the corresponding numbered pumping units.

Note: All damaged pipework should be replaced using genuine spare parts, failure to do so can cause system malfunctions and major safety issues.

Standard Pump Elements for AX1 & AX2 pumps.

Part No. Output/stoke Color Outlet Size

78033-PL 0.010 cc Red

4mm OD

Push Type

78034-PL 0.015 cc Green

78035-PL 0.025 cc Yellow

78036-PL 0.040 cc Blue

78037-PL 0.060 cc Grey

78038-PL 0.10 cc Black

Output pressure

Maximum Output pressure from

each Pump Element 1740PSI / 120 Bar


Installation

To connect the lubricant distribution lines to the bearing, as detailed on the previous page, remove the existing grease

nipple(s) (see images 1 & 2, below) and replace with the preferred push-fit or compression fitting(s) (see images 3 & 4,

below). A choice of fittings are available to suit all requirements (see page 8—Accessories).

Typical System Installation Methods

1 2 3 4

The AXL systems are suitable for use with most bearing types and brushes, for chain

lubrication or sliding parts.

If a lubrication distribution line is not required simply remove the line (securing loose end with a cable tie around the

rest of the loom) remove the pumping unit and replace with a blanking plug (part number 34237-402). See steps below:

4

2 1

3

SUFFIX

TOTAL CYCLE TIME

(mins.)

PCB SWITCH POSITION

1 2 3 4 Run time

(mins.)

Delay time

(mins.)

1 12 MINS ON - - - 6 6

2 21 MINS - ON - - 6 15

3 36 MINS - - ON - 6 30

4 66 MINS - - - ON 6 60


Installation

Green = Earth

Black = Live (+110V)

White = Neutral (-0V)

To access the internal PCB and adjust the run settings, via the dip switch:

1) Disconnect power to the pump.

2) Remove lid screws x3 (see ‘A’), (Torqued to 0.6Nm).

3) Remove lid (see ‘B’), making sure to retain the O-ring.

4) Remove motor housing screws x4 ( see ‘C’), (Torqued to 1.2Nm). Make sure to retain the O-ring.

5) Access PCB (‘D’) and adjust dip switch as required (see PCB 83344-426 image, at the bottom of this page, for the location of the dip switch).

6) Re-assemble, ensuring the drive adaptor locates on the paddle and the O-rings are correctly fitted.

A

C

B

D

Wiring Information

DIP SWITCH

PCB 83344-426

PCB Adjustments

PCB 83344-426 settings table:

The Pump cycle time can be changed from the factory set option, if required. The above table shows the settings available via setting of the dip switch on the PCB (see left hand image).

Switch positions ‘1-4’ cycle times are based on the delay period. Pump runs for 6 minute cycles before the specified dwell time then repeats.

Note that only 1 switch can be in ‘on’ position at a time.

Having all switches in ‘off’ position will cause the pump to run one cycle (6mins) and delay indefinitely, or until power is switched off.


System Overview and Operation The Interlube AXL range has been designed to provide reliable and virtually maintenance free service in the most demand-

ing applications. The system is an electrically operated (110/240V) pump with integral controller and one or more lubricant

distribution lines, which connects each bearing directly to the respective pumping unit, via a bulkhead fitting situated on

the sides of the mounting bracket.

Each bearing is fed independently, meaning that the lubrication amounts to the respective points can vary depending on

the specific pumping unit selected. It also means that damage to one lubricant distribution line does not affect the rest of

the system.

The motor drives the paddle blade, which pushes grease into the pumping chamber and provides a visual indication of the

pumps operation. The motor also drives the cam(s), which operates the individual pumping units and feeds the grease into

the lubricant distribution lines. Each lubricant injector is actuated by its cam once every 360° revolution.

The lubrication process starts after the power to the pump is switched on and after the allotted dwell time (of the already

programmed pump) has elapsed. The pump will run for 6 minutes and dwell for the allotted time as programmed (6

minutes dwell if 6 minute program, 15 minutes dwell if 15 minute program, etcetera).

If the power drops out at any time to the pump the counter will be stopped and the program will restart when the power

resumes.

An indication lamp is located on the top of the pump (marked ’A’ below), within a viewing window. The indication light will

be lit when there is a continuous supply to the circuit and pump.

The following inspection procedures are recommended to help ensure proper operation of the AX industrial lubrication

system. Once the reservoir refill period has been determined (see page 6, Typical Refill Periods) make certain that the

interval is part of your scheduled maintenance.

Inspect all lubrication points for signs of FRESH grease,

Check the condition of all fittings and connections. Tighten or replace loose or damaged fittings.

Check all lubrication lines; make certain that there are not any breaks. Check for wear or chaffing that may lead to

leakage.

If, during these checks, any issues are found use the Lubrication Troubleshooting Chart on page 11 to help resolve them.

Operation

A


Operation

Calculation:

(NxO1) + (NxO2) + (NxO3) + (NxO4) + (NxO5) + (NxO6) = A

E=R1 or R2 A E x P = Total Runtime in minutes (T) until empty

T / 60 = Total Runtime in hours (H) until empty

H/24 = Total Runtime in days (D) until empty

Example:

An AX1 (R1) with a 0.167 RPM motor (M) calibrated with 2 Red P.U.

(O1), 4 Yellow P.U. (O3) & 6 Grey P.U. (O5) programmed for a 36 minute

cycle time.

((2x0.01)+(4x0.025)+(6x0.06)=0.48cc

1250cc/0.48cc = 2604.16 Revs

2604.16x36 = 93749.76 minutes until empty

93749.76 / 60 = 1562.5 hours until empty

1532.5 / 24 = 65.1 days between refills

*Note that this calculation is based on the pump having an -

uninterrupted power supply and being in continuous operation*

Periodic System Inspection A program of visual checks, regular inspections and servicing should be incorporated in accordance to the assets existing

maintenance schedule. Maintenance staff should be encouraged to check automatic lubrication on a periodic basis and report any defects.

Recommended Lubricants The AX pump has been developed specifically to run with NLGI Grade 000, 00, 0, 1 and 2 greases. Oils to a minimum viscosity

of SAE80 are also acceptable. Do not use heavy, tackified greases, greases containing bentone/bentonite or greases containing

molybdenum and/or graphite.

NOTE: To ensure proper operation of the lubrication system only ever fill with clean lubricant that has been in a sealed container and correctly stored. To abstain from clean lubricant can result in premature system or bearing failures.

Recommended Lubricants Operational Temperatures

(Based on maximum lubricant distribution line length of 60ft /18m)

Typical Refill Periods

The AX1 & AX2 refill periods range greatly, dependent on the number of pumping units as well as output quantities and cycle

times. Due to the accuracy of output quantities and the reliability of pump functionality refill periods can be simply calculated

to ensure that the pump and the bearing points don’t run dry. Use the following to calculate refill periods:

Key:

N = Number of Pumping Units (P.U.) 1-36.

O1= Red P.U. with Output 0.01cc

O2= Green P.U. with Output 0.015cc

O3= Yellow P.U. with Output 0.025cc

O4= Blue P.U. with Output 0.04cc

O5= Grey P.U. with Output 0.06cc

O6= Black P.U. with Output 0.10cc

A = Total Output Amount per 1 revolution

E = Number of revolutions until Empty

R1= 1250cc AX1 Reservoir

R2= 2000cc AX2 Reservoir

P = Programmed cycle time (12, 21, 36 or 66 minutes).

Pump Type Recommended Lubricants

Oils SAE 80/90 000 Fluid 00 Semi Fluid 0 Soft 1 Stiff 2 Hard

AX2XX1 -40°C -35°C -30°C -25°C -20°C -15°C

AX2XX2 -30°C -25°C -20°C -15°C -10°C -5°C

AX2XX3 -20°C -15°C - - - -

AX1XX1 -40°C -35°C -30°C -25°C -20°C -15°C

Upper Temp

Limit +40°C for all pumps

Select only one

Maintenance


Pump Refill Procedure

1

2

Date & Time Service Engineer Sign / Stamp Refill Quantity Lubricant Used

All Interlube Systems’ multiline pump options are fitted with both a bulk fill cap (see image ‘1’ below), which is suitable for oil and fluid grease up to NGLI ‘000’ and a bottom fill, grease nipple, adaptor (see image ‘2’ below, right) for filling with grease up to NGLI Grade 2. Using the grease nipple adaptor for grease fill avoids the possibility of air entrapment and cavitation. Bulk fill adaptors are also available on special request, which can be fitted instead of the grease nipple as shown on the examples below. IMPORTANT NOTES:

If the reservoir is filled through the reservoir bulk fill cap ensure that the cap is firmly secured to the reservoir lid when finished.

If the reservoir is filled through the grease nipple ensure that it is cleaned first. Place the dust cap back on the nipple when finished.

Do not overfill the reservoir. Fill only to the MAX Level Label.

Pump Refill Schedule Log

Fittings and Accessories


Elbow Connectors

Accessories

Part Number Thread Size

PM90412-NP 1/8” NPT

PM90484-ST 1/4” x 28UNF

PM90485 5/16” x 24UNF

PM90487 1/8” BSPT

PM90489 M6 x 1

PM90490 M8 x 1

PM90491 M8 x 1.25

PM90492 M10 x 1

PM90493 M10 x 1.5

Straight Connectors

Part Number Thread Size

PM80412-NP 1/8” NPT

PM80484-ST 1/4”x 28UNF

PM80485 5/16”x 24UNF

PM80487 1/8” BSPT

PM80489 M6 x 1

PM80490 M8 x 1

PM80492 M10 X 1

Conduit / Spiral Binding

Part Number Description

20030 1/4” Spiral binding (for 1 tube)

20034 3/8” Spiral binding (for 2-5 tubes)

20031 1/2” Spiral binding (for 6-12 tubes)

20032 3/4” Spiral binding (for 13+ tubes)

39694A250 1/4” Split Conduit (for 1 tube)

39694A375 3/8” Split Conduit (for 2-4 tubes)




39694A1000 1” Split Conduit (for 20-34 tubes)

Grease Filled Nylon Tube


152057-164 Ø4mm OD Unprimed 164ft.

152823-164 Ø4mm OD Grease Filled (NLGI00) 164ft.

152823/FG-164 Ø4mm OD Grease Filled (Food Grade) 164ft.

38508A1 Cable Tie (7” Length)

1755-830 Black electrical tape (1” Width)

Numbered Sleeve


39257-A1 For up to 12 point system



Note: Actual connectors may vary from images.

Spare Parts


1

2

3

4

5

6

7

8

9

10

11

12

Spare Parts


AXL Pump Assembly Spares

Item

No. Part No. Description Qty.

1 AX/SP1 AX LID AND SEALS ONLY 1

2 AX/SP2 PCB ASSEMBLY 83344-426 1

3 AX/SP3/110V

AX/SP3/240V ELECTRIC MOTOR 1

4 AX/SP15 LID, MOTOR & PCB ASSEMBLY (110V & 240V) 1

5 AX/SP4 AX1 RESERVOIR 1

6 83341-805 BRACKET 1

7 AX/SP-9

AX/SP-6

PADDLE ASSEMBLY

DRIVE ADAPTOR 1

8

AX/SP5-1

AX/SP5-2

AX/SP5-3*

CAMSHAFT ASSEMBLY (12 PORT)



1

9 34237-402 BLANKING PLUG 1-23

10

78033-PL

78034-PL

78035-PL

78036-PL

78037-PL

78038-PL

PUMPING UNIT—0.010cc






1-24

11

32478-202

32478-203

32478-204*

MANIFOLD (12 PORT)

MANIFOLD (24 PORT)

MANIFOLD (36 PORT)

1

12 83416-037 GREASE NIPPLE FILL POINT 1

13 25487-072 (Not Shown) BULKHEAD FITTING M13x1 1-36

14 34237-469 (Not Shown) 4mm PUSH FIT BLANKING PLUG FOR ITEM 13 2-36

* Check with supplier the suitability of a 36 point, AX13X1-50 or –51 system and it’s likely application.

† Parts are on AXL pump bracket.

†

Problem Cause Solution

1. Inoperative Pumping Ele-ment.

a) Inoperative Pump a) Refer to “Problem A” in ‘Electrical—

Troubleshoot’

b) No Grease flow b) Replace pumping unit

2. All lubrication points appear

dry.

a) Empty reservoir a) Refill the reservoir, using the correct

lubricant.

b) Inoperative pump b) Refer to “Problem A.”

c) Time between lube cycles is too long. c) Adjust pump CYCLE TIME setting.

d) Reservoir filled with an unsuitable lubricant.

d) Remove the lubricant and replace with correct grade of lubricant.

e) Inoperative Pumping Unit e) Replace Pumping Unit

f) Reservoir vent blocked from over filling. f) Clear vent and only fill to max level.

3. Pump is working, but does

not supply lubrication

a) Grease level dropped below minimum level a) Bleed the pump & refill the reservoir

b) Defective pumping element b) Replace the pump element

4. No grease at all points of

lubrication

a) Pump does not work. a) Refer to “Problem A.”

b) Dwell time is too long or b) Reduce the system dwell time.

c) Lubrication quantity is too little. c) Change the pumping unit with an

increased output.

d) System is blocked. d) Refer to “Problem A.”

5. No grease at some points of

lubrication

a) Some pipes are burst or leakage at pump-ing unit unions to pipework.

a) Renew the pipes.

b) Blocked or broken pumping unit. b) Determine defective pumping unit and

replace.

6. No grease at one point of

lubrication

a) The lubrication pipe is burst or leaking a) Renew the pipe

b) Leakage at union point b) Retighten or renew the screwed union

7. Lubrication points are over-

lubricated. a) Incorrect pumping unit output.

a) Re-configure pumping unit for lower output quantity.

8. Excessive pressure of the

System.

a) Excessive pressure in the system caused by blockage in the system.

a) Check the system

b) One or more lubrication points are blocked and will not accept grease.

b) Remove pipe from fitting and flush bearing through with grease gun.

9. All lubrication points are

over lubricated.

a) Incorrect setting of “on-time” or “Delay Time”.

a) Reduce “On Time” or increase Delay Time”, or both.

Troubleshooting

Lubrication Troubleshooting Chart


Troubleshooting


Electrical Troubleshooting Chart

Problem Cause Solution

A.) Pump Does Not Work.

a) No input power. a) Check for power to the pump and controller.

b) Loose / broken wire connection inside the pump.

b) Check all wires and connections in the pump.

c) Defective PLC. c) Replace Controller Assembly.

d) Defective Motor. d) Replace Motor.

e) Fuse doesn’t work. e) Replace fuse (1.Amp)

B.) Reduced Pump Speed.

a) High pressure in the system a) Check the system / bearing points

b) Low ambient temperature b) Not a defect (1 or 2 lubrication cycles may be required)

INSTALLATION RECORD

Pump No……………………………………………………………………………... Customer……………………………………………………………………………. Voltage………………………………………………………………………………...Timer Setting………………………………………………………………………..

Unit

No. Bearing location

Col.

Code

Cal.

CC

Unit

No. Bearing Location

Col.

Code

Cal.

CC

1 19

2 20

3 21

4 22

5 23

6 24

7 25

8 26

9 27

10 28

11 29

12 30

13 31

14 32

15 33

16 34

17 35

18 36

The Timken team applies their know-how to improve the reliability and performance of machinery in diverse

markets worldwide. The company designs, makes and markets high-performance mechanical components,

including bearings, gears, chain and related mechanical power transmission products and services.

Stronger. Commitment. Stronger. Value. Stronger. Worldwide. Stronger. Together. Stronger. | By Design.

Timken® is a registered trademark of The Timken Company. | © 2017 The Timken Company | Printed in U.S.A.

www.timken.com/interlube

ax1331-50/51 installation manual - · pdf filetimken -luri ation installation manual for...

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